Insulated Shipping Container

ABSTRACT

An insulating container is disclosed. The insulating shipping container includes an outer container and pieces of laminated foam, which are cut or scored to create hinges that permit the laminated foam pieces to be configured into an insulating enclosure. Alternatively, the laminated foam pieces may be formed without hinges and friction fit into the outer container.

CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM

This application is based on and claims priority to U.S. Provisional Application No. 61/346,231 filed on May 19, 2010, which is incorporated herein in its entirety for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to the field of insulated shipping containers.

BACKGROUND

The prior art contains numerous examples of coolers and shipping containers with a variety of configurations. Nevertheless, a need exists for a shipping container that has improved thermal properties and that is efficient to manufacture.

Both expanded polystyrene foam (“EPS”) and extruded polystyrene foam (“XPS”) are known for their thermal insulating properties and are widely used as insulating materials. It is also known that combining or impregnating foam polymers with other materials can improve the thermal properties of foam. For example, impregnating styrene polymers with graphite is now known to enhance the insulating properties of foam. See, e.g., U.S. Pat. Nos. 6,130,265; 6,340,713; 6,384,094; 6,414,041, 5,977,197, 5,582,781, and U.S. Publication No. 2006/0189703 which are incorporated herein by reference for all purposes. An example of one commercially available graphite impregnated foam is NEOPOR® by the chemical company, BASF. NEOPOR is a graphite impregnated expanded polystyrene foam. The graphite flakes in NEOPOR foam reflect heat radiation, and therefore improve the thermal insulation properties of the foam. Graphite impregnated foam has greater thermal insulating ability than regular foam and helps to keep frozen items frozen during shipping or to keep warm items warm. The ability to maintain the temperature of the contents of the container without the use of ice or other agents is advantageous because such containers are lighter weight, and cost less to ship.

It is also known in the prior art to use foam panels or foam as the insulation material for shipping containers. See, e.g., U.S. Pat. Nos. 3,890,762; 4,497,859; 4,682,708; 6,325,281. Some of these prior designs use mitred, hinged, or scored panels as an insulation material. See, e.g., U.S. Pat. Nos. 5,441,170, and 3,980,005. It is also known in the prior art to use U-shaped padding or insulation panels. See, e.g., U.S. Pat. Nos. 4,033,806; 4,928,847; 5,111,957; and 5,201,868. However, these hinge and panel shape designs are generally complicated and inefficient to manufacture, or time consuming to disassemble and assemble. The existing shipping containers and insulating methods, therefore, have significant shortcomings, and there is a need for a shipping container that has improved thermal properties, which is simple to assemble or disassemble, is reusable, and is efficient to manufacture.

It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the outer container and the two laminated foam pieces of one embodiment of an insulated container in accordance with the present invention.

FIG. 2 is a perspective view showing the inner surfaces of the two laminated foam pieces of the container shown in FIG. 1.

FIG. 3 is a perspective view of the two laminated foam pieces of the container shown in FIG. 1, showing the hinges of the laminated foam pieces.

FIG. 4 is a perspective view of one of the laminated foam pieces from the container shown in FIG. 1, showing the piece in a folded position.

FIG. 5 is a perspective view of the laminated foam piece shown in FIG. 4, with the ends of the outer panels flush with the surface on which the piece is resting so as to complete the corner.

FIG. 6 is a perspective view of one of the laminated foam piece shown in FIGS. 4 and 5, in the outer container.

FIG. 7 is a perspective view of the two laminated foam pieces of the container shown in FIG. 1, demonstrating how the two pieces can be positioned to provide an insulating enclosure within the outer container.

FIG. 8 is a perspective view of the two laminated foam pieces of the container shown in FIG. 1, showing how the two laminated pieces provide the insulating enclosure when the pieces are in the outer container.

FIG. 9 is a perspective view of the top of a laminated foam piece inside the container shown in FIG. 1, shown positioned to provide an insulating enclosure with a lid, and positioned inside the outer container.

FIG. 10 is a flow chart drawing showing one way to fold the laminated foam pieces to assemble the container shown in FIG. 1.

FIGS. 11 a and 11 b are perspective views of an alternative assembly configuration for the two laminated foam pieces of the container shown in FIG. 1.

FIGS. 12 a and 12 b are perspective views of an alternative embodiment of laminated pieces cut to fit within an outer container (not shown).

DETAILED DESCRIPTION

In one embodiment of the invention, shown in FIGS. 1-9, an insulated shipping container comprises an outer container 1, and two laminated foam pieces 2, 3. The laminated foam pieces are scored to provide hinges 4 that enable the laminated foam pieces 2, 3 to be configured into an insulating enclosure 5. In one embodiment of the invention, the insulating enclosure 5 is a square or rectangular shape. Thus, one of the laminated foam pieces 2 has a slightly smaller dimension than the other laminated foam piece 3, so that the two can be configured into the cuboid insulating enclosure, as shown in FIGS. 7 and 8. Although the embodiment shown in FIGS. 1-9 employs two laminated foam pieces and a box for an outer container, it is understood that other numbers of laminated foam pieces may also be used (for example, the alternative embodiment shown in FIGS. 12 a and 12 b, as well as other shapes of outer containers.

The outer container 1 can be any type of container, such as a box, bag, compartment, or any other item or enclosure that can contain matter. As best seen in FIGS. 4 and 5, the laminated foam pieces 2, 3 comprise a foam core 6 at least partially disposed between laminate facers 7. The foam core 6 may be manufactured from any suitable variety of expanded polystyrene (“EPS”), which may be modified, unmodified, colored, or impregnated with other materials such as graphite (e.g., NEOPOR), and of any density; extruded polystyrene (“XPS”) of any density, compressive strength, or color; Urethane (polyisocyanurate); or any other suitable foam material. The laminate facers 7 may be manufactured from polypropylene PP, polyethylene PE, polyethylene terephthalate PET (polyester), high density polyethylene HDPE, linear low density polyethylene LLDPE, or polyamide (nylon), or materials such as aluminum foil with a paper or polymer backing, or any other suitable laminate material. Different or the same materials can be used on opposite sides of foam core 6. Further, any polymer used as a material for laminate facers 7 may be in any of the following forms: extruded, blown, oriented, non-oriented, metalized, plain, printed, woven, non-woven, as part of a structured film, or used alone. The aforesaid laminated foam pieces 2, 3 can be manufactured by a variety of processes, including, but not limited to: heat lamination, hot melt lamination, or cold glue lamination (using urethane, latex, or other glue).

In accordance with one embodiment of the invention, the laminated foam pieces are prepared as follows. The desired thickness of the foam core 6 is selected, and the foam core sized or cut to the desired size. The laminate facers 7 are joined to the foam core 6, so that the foam core is at least partially disposed between laminate facers 7. The inner surface 8 and outer surface 9 of the foam core 6 can be joined to the laminate facers 7 using any suitable method, including, but not limited to heat-laminating, cold glue, etc.). In a preferred embodiment of the invention, the foam core 6 is essentially a sheet of foam, which is at least partially laminated on the inner and outer surfaces, namely the broad surfaces, of the sheet. Additionally, the laminate facers 7 on the two sides of a foam core are preferably different materials, having different melting points. The reason for this is to avoid having the parts stick together when they are cut or scored to create hinges. For example, one panel may be laminated with polypropylene and the other panel may be laminated with polyester. It would also be possible to only provide lamination on one side of the panel (the hinged side) but the panel would then have diminished insulative characteristics.

Then an operation is performed to cut the laminated foam into laminated foam pieces having the desired length and width, which is selected based on the size of the outer container. For efficiencies in manufacturing and cutting, the laminated foam may be stacked so that the panel surfaces are face-to-face, but the surfaces that are touching are not the same laminate material. If hot wires or other heated devices are used to cut the laminated foam to the desired length and width, the cut edges of laminate facers will not become melted together during cutting if the adjacent laminate facers are not the same material. Of course, if hot wires or other heated devices are not used to cut the laminated foam to length and width, the laminate facer materials on each side of the laminated foam can be the same.

Once the laminated foam pieces 2, 3, are prepared, they are then cut or scored to create hinges 4. The hinge positions are established to make the cut pieces fit properly into the designated outer container, which is integral to making the insulated shipping container function as intended. The hinges 4 are cut or scored into the laminate foam pieces 2, 3 at the appropriate locations using a slitter blade or hot wire apparatus. In cutting the hinges, it is imperative that one of the laminate facers remain intact (uncut). Once hinges are cut, the hinges define subsections of the foam core. In one embodiment of the invention (see FIGS. 3-5), each laminated foam piece has three subsections, namely one central subsection 10, and two outer subsections 11, 12. These subsections are free to be moved and positioned into an insulating enclosure, and are held together by the intact laminate facer, which also functions as a hinge. A variety of methods may be employed in order to score or cut the laminate facers and foam core to create the hinges, including, but not limited to: a slitter blade (round, straight, smooth, toothed,) or a hot wire cut, or any other suitable way of cutting laminate and foam materials.

The laminated foam pieces 2, 3 are then prepared into the desired configuration and packed into the outer containers. There are multiple simple ways to assemble the laminated foam pieces into the insulating enclosure. One way is shown in FIGS. 6-10 and another is shown in FIGS. 11 a and 11 b. There are, of course, many other variations of using laminated foam pieces to create an insulating enclosure, including varying the number of laminated pieces, the number of hinges, and/or the configuration of the insulating enclosure.

FIGS. 3-5, and 10 best illustrate the function of the hinges. The hinges 4 allow the subsections of the laminated foam pieces 2, 3 to be positioned so that the edges of the insulating enclosure 5 are flush with the surfaces of the outer container 1. FIG. 4 shows laminated foam piece 3 with the outer subsections 11, 12 bent at the hinges 4 (laminated foam piece 2 bends in a similar manner). FIG. 5 shows laminated foam piece 3 with the outer subsections 11, 12 bent at the hinges 4 and positioned flush with the adjacent surface. The same function allows the laminated foam pieces 2, 3 to be positioned to provide a complete thickness of insulation at the corner, and can include a complete barrier in the uncut laminate facer.

As shown in FIGS. 6-9, and 10, two laminated foam pieces 2, 3 are used to form an insulating enclosure 5. Each laminated foam piece is scored to have two hinges 4, which define three subsections of the laminated foam piece 10, 11, 12. One of the laminated foam pieces 3 (the larger one) is placed into the outer container 1, for example, a box, so that one of the outer subsections 12 of the laminated foam piece is flush with the bottom of the box. See FIG. 6. Central subsection 10 is also pushed down so that edge of subsection 10 is flush with the bottom of the box. Laminated foam piece 2 (the smaller one) is then bent at the hinges to form a C-shape or U-shape and inserted into the outer container 1 so that the two laminated foam pieces 2, 3 form an insulating enclosure 5. See FIG. 7. The hinges of laminated foam piece 2 function in the same way as those in laminated foam piece 3, and as shown in FIGS. 4 and 5. In this configuration, subsection 11 of the laminated foam piece 2 then is capable of functioning as a lid. The laminated foam pieces may be assembled inside of the outer container, as just described, or may be assembled outside of the outer container and inserted into the outer container. Laminated foam pieces may also be assembled into different configurations, or in a different order, such as inserting one of the laminated foam pieces in a U-shape into the bottom of the box, and another laminated foam piece over it, as shown in FIGS. 11 a and 11 b. Materials may be inserted easily into the insulated enclosure for storing or shipping. The laminated foam pieces and outer container are also easily reusable.

As best seen in FIG. 5, the corners that are created by the present configuration provide a significant advantage over the known prior art corner configurations in that they are easily manufactured and then formed in place, provide a complete thickness of insulation at the corner, and can include a complete barrier in the uncut laminate facer.

One additional embodiment of the invention is show in FIGS. 12 a and 12 b. In this embodiment, laminated foam pieces are cut to dimensions such that they can snugly fit together in a friction fit when placed in an outside container. In this embodiment, the benefits of the additional insulating effects of the laminated foam are realized but the corners are not sealed to provide the complete barrier shown in FIG. 5. This embodiment exhibits significantly improved insulating effects as compared to using conventional foam insulation.

The present invention may be used in a variety of applications. For example, it may be used as a shipping container to keep its contents hot or cold during shipping or transport. Contents may include food, beverages, biological materials, medicines, or chemicals. The thermal properties of the insulation used will of course depend on the thermal properties of the foam core and laminate materials. However, the use of a foam core comprised of graphite impregnated EPS should be sufficient to keep food or biological products cold, frozen or warm during typical transport. The shipping container may also be used for storage, and the insulation used for packing or protection. The laminated foam pieces may also have other insulating uses in shipping or packing applications.

Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein. 

1. An insulated container comprising: an outer container; and a plurality of laminated foam pieces, the laminated foam pieces each having a foam core with a first laminated face covering a side thereof; the laminated foam pieces having at least one hinge created by a score in the foam core that does not extend through the first laminated face; and wherein the laminated foam pieces are folded at the at least one hinge so as to create an insulating enclosure, the insulating enclosure positioned within the outer container.
 2. The insulated container of claim 1 further comprising a second laminated face covering a side of the foam core opposite of that covered by the first laminated face.
 3. The insulated container of claim 1 wherein the foam core is a graphite impregnated expanded polystyrene.
 4. The insulated container of claim 2 wherein the first laminated face and the second laminated face are made from different materials.
 5. The insulated container of claim 4 wherein the first laminated face is made from a material with a melting point higher than that of the second laminated face.
 6. The insulated container of claim 4 wherein the first laminated face is made from polypropylene and the second laminated face is made from polyester.
 7. A method of assembling an insulated container comprising the steps: selecting an outer container; selecting a first laminated foam piece and a second laminated foam piece; folding the first laminated foam piece along a hinge; placing the partially folded first laminated foam piece into the outer container; folding the second laminated foam piece along two hinges; placing the folded second laminated foam piece into the outer container; and folding the first laminated foam piece along a hinge.
 8. A method of manufacturing an insulating enclosure comprising the steps: preparing a foam core by shaping it to a desired thickness; joining two laminate facers to the outer panels of the foam core to form laminated foam pieces, wherein each of the laminate facers are comprised of different materials; stacking the laminated foam pieces so that the laminate facers are not touching the same type of laminate facer material; cutting the laminated foam pieces to the desired length and width; and cutting hinges into the laminated foam pieces at appropriate locations in order for the laminated foam pieces to be configured into an insulating enclosure wherein edges of the foam core adjacent to the hinge are flush with the surface of the outer container. 